modular assembly

ABSTRACT

A modular assembly capable of converting from a shipping container configuration into a building unit, and from a building unit into a shipping container configuration. From the shipping container configuration, a plurality of frame panels and unit panels moveably connected to a frame of the modular assembly are selectively positioned to form the floors, walls, and ceilings of the building unit configuration thereby forming a living and/or commercial structure complete with electrical, water and sewage connections. The assembly may include an automated erection system, which may include a system of electric motors, gears, pulleys, cables, automated mechanical arms and electronic controls, located within the container structure of the modular assembly, and which interact with a plurality of frame panels and unit panels to deploy and retract the plurality of frame panels and unit panels for constructing the shipping container configuration and building unit configuration.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit/priority from U.S. application Ser. No.12/604,136, filed Oct. 22, 2010, the entire disclosure of which isincorporated herein by reference in its entirety. U.S. application Ser.No. 12/148,914, filed Apr. 23, 2008, published as US 2009/0266066 onOct. 29, 2009, is also incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the field of modular assemblies, andmore particularly, relates to a modular assembly structured to assumeeither a shipping container configuration or a building unitconfiguration.

2. Description of the Related Art

Building units are an essential part of everyday life. Houses come inall shapes and sizes, and can be made in various ways from various typesof materials. Traditionally, building units are constructed from theground up in a specific location, for that location. These types ofbuilding structures can take weeks or months to construct, requiringmany different types of materials and construction phases to complete.Once complete, the building structure remains at its specific locationas a then permanent fixture of the landscape.

Recent developments in materials and structural engineering have allowedhome builders to construct “mobile” homes: prefabricated, full-sizedhousing structures that can be transported to a specific location. Thesemobile homes are assembled in substantial part before being delivered tothe specific location. Mobile home transportation requires a “wide-load”configuration involving tractor-trailers as well as lead and followvehicles. Once at the home site, the mobile home must be furnished andconnected to local utilities, such as electrical, water and wasteremoval systems. The mobile home, once delivered to a specific location,becomes a permanent fixture of the landscape. The advantage topre-fabricated housing structures lies in the ease of construction.Mobile homes are not constructed at a specific location over weeks ormonths, but are constructed in a factory, and simply shipped to thespecific location. The disadvantages include complex and tenuoustransportation.

Portable building units have been around for decades. Lightweight,easily transportable structures provide temporary shelter from theoutdoor environment. However, natural disasters and other catastrophescan destroy dwellings, thereby creating a need for fully equippedemergency shelters. These emergency shelters need be easily transportedand easily set up in matter of hours. The disadvantages thus far toportable, foldable building units have been numerous: difficult totransport folded configurations; multiple loose panels, multiple unitsections, and difficult hinging and fastening mechanisms; difficult toassemble panels and elements; and a lack of utilities inside the unit.Many recent attempts at portable, foldable building units have led onlyto exterior structures; once unfolded, the building unit provides ashell dwelling with none of the necessary amenities most homes require.Previous attempts at portable building units have also affordedhard-to-assemble structures that require special tools and sectionalconstruction.

Accordingly, there is a need in the portable building units industry fora modular assembly capable of convenient transport, and ready for easyassembly by as little as one person with no special tools or equipment,and fully equipped with utilities necessary to properly, andimmediately, house occupants. The building unit need be large enough tooccupy as a dwelling, yet compact and portable enough to be transportedto and set up on many different locations. The building unit also needbe equipped with utility connections to immediately take advantage ofwater, sewer, and electrical utilities.

SUMMARY OF THE INVENTION

Exemplary embodiments of the present invention overcome the abovedisadvantages and other disadvantages not described above. Also, thepresent invention is not required to overcome the disadvantagesdescribed above, and an exemplary embodiment of the present inventionmay not overcome any of the problems described above.

One aspect of the present invention provides a modular assembly with anautomated erection system capable of converting from a shippingcontainer configuration into a building unit with utility connections,and from a building unit into a shipping container. The automatederection system may be pre-programmed with the automatic sequence. Fromthe shipping container configuration, a plurality of frame panels andunit panels are selectively positioned to form the floors, walls, andceilings of the building unit configuration thereby forming a livingand/or commercial structure complete with electrical, water and sewageconnections. The building unit can then also be folded and convertedback by the automated erection system by a substantially reverse processinto the shipping container configuration for transport to and fromvarious sites.

The automated erection system may include a system of electric motors,gears, pulleys, cables, automated mechanical arms and electroniccontrols, located within the container structure of the modular assemblyand which interact with the plurality of frame panels and unit panels todeploy and retract the plurality of frame panels and unit panels forconstructing the shipping container configuration and the building unitconfiguration. Thus, the modular assembly may be selectively disposedand oriented into either a shipping container configuration or abuilding unit configuration via the automated erection system, whichfacilitates the conversion.

As noted above, the building unit configuration is also complete withelectrical, water and sewage connections. From the building unitconfiguration, the unit can be then folded and converted into a shippingcontainer configuration for transport by a variety of appropriatetransportation means. Moreover, the modular assembly of the presentinvention can be stored and/or transported when in the shippingcontainer configuration.

In the various exemplary embodiments of the modular assembly, both theshipping container and the building unit configurations comprise a frameat least partially defined by a plurality of support members,interconnected by cross braces or the like, and that form a box-like orother appropriate shape. The support members and cross braces preferablycomprise elongated, relatively high strength material memberspreferably, but not exclusively, in the form of steel rectangular tubeswelded together to collectively comprise the stable, rigid frame.

Within the support members located on each corner of the modularassembly, extensible columns operated by automated electromechanicalactuators lift and level the modular assembly raising it, preferably, atleast eighteen inches off the ground and adapting it to a variabletopography site such that the bottom panel (i.e., the floor of thebuilding unit) is level. Each extensible column can be independentlyadjusted to adapt its height to fit the terrain. Thus, the modularassembly can be leveled without modifying the land itself, leaving theland in its original state.

A plurality of pressure pads are located underneath the columns,connected to the ends of the extensible columns, to distribute theweight of the modular assembly and to prevent the columns from sinkinginto the soil. Again, not only do the pressure pads help to keep themodular assembly level, but also reduces any damage to the land. It ispreferable that only four extensible columns with pressure pads be usedsuch that the impact on the land is reduced.

Once the modular assembly having a shipping container configuration islocated at a construction or assembly site and the extensible columnsare locked into their extended positions, the modular assembly is readyfor disposition into the building unit configuration. Accordingly, themodular assembly of the present invention includes a plurality of framepanels as well as a plurality of unit panels each at least initiallydisposed in a closed orientation on or within the box-like frame. In atleast one exemplary embodiment the frame panels and unit panels areformed from a load-bearing material such as corrugated steel or otherappropriate material.

The plurality of frame panels include at least one but preferably twoside panels each of which may define the “long sides” of the frame whenin the shipping container configuration. These frame panels, may alsodefine the side floor portions of the building unit configuration whenso assembled (to be described later). Accordingly, the one or more framepanels are pivotally or hingedly attached along their lower mostlongitudinal (i.e., horizontal) end to the frame and are selectivelypositioned or pivoted outwardly therefrom in a downward direction torest in a substantially horizontal position. These frame panels arelowered (or raised) by a plurality of cables of the automated erectionsystem. When in the intended operative position, the frame panels definethe floor portions of the building unit configuration.

In addition to the above, the modular assembly further comprises aplurality of unit panels at least some of which are movably connected tothe frame and initially disposed on the interior thereof when themodular assembly is in the shipping container configuration.

A first set of the plurality of unit panels are exposed after the framepanels are deployed from their shipping container configuration. Thefirst set of the plurality of unit panels are pivotally or hingedlyattached along their upper most longitudinal (i.e., horizontal) end tothe frame and are selectively positioned or pivoted outwardly therefromin an upward direction to rest in a substantially horizontal position,into a position which overlies the floor portion defined by theaforementioned frame panels. Thus, when deployed, the first set of theplurality of unit panels form a ceiling portion of the building unitconfiguration. The first plurality of unit panels are raised (orlowered) by a plurality of automated mechanical arms which arecontrolled by a plurality of cables of the automated erection system.

Further, each of the side panels of the plurality of frame panelsinclude panel segments initially disposed in overlying confrontingrelation to respective ones of the frame panels. The panel segments ofcorresponding ones of the frame panels or side panels are hingedly orpivotally attached at the outer longitudinal edge of the frame panel(i.e., at the upper most longitudinal end of a frame panel whenpositioned in the shipping container configuration) so as to extendoutwardly in an upward direction from the corresponding frame panelsinto a substantially upright (i.e., vertical) position. The panelsegments are raised (or lowered) by a plurality of cables of theautomated erection system. Further, when erected to the substantiallyupright position, a longitudinal edge or portion of the now uprightpanel segments are connected to and support a corresponding outerlongitudinal edge of the first set of the plurality of unit panels.

In one exemplary embodiment, the first set of unit panels are deployedbefore the deployment of the panel segments to their upright position.

As such each of the combined or directly associated frame panels andpanel segments collectively define a corresponding floor portion andlong sidewall portion of the building unit configuration. Furthermore,the first set of the plurality of unit panels define a correspondingceiling portion supported by the long sidewall portion of the buildingunit configuration (i.e., by the uprighted panel segments).

Additional ones of the plurality of unit panels (i.e., a second set ofthe plurality of unit panels) may also be movably connected to the frameand are at least initially disposed on the interior thereof when themodular assembly is in the shipping container configuration. Inparticular, the second set of the plurality of unit panels are exposedafter the first set of the plurality of unit panels are deployed fromtheir shipping container configuration. In at least one exemplaryembodiment the second set of the plurality of unit panels may bepivotally or hingedly connected along a latitudinal (i.e., vertical)edge or side thereof to the frame structure (e.g., to a support memberof the frame structure) and may extend outwardly so as to respectivelydefine front wall portions and rear wall portions of the building unitconfiguration. The second set of the plurality of unit panels arerotated outward by means of electromechanical actuators of the automatederection system to assume their positions as front wall and rear wallportions of the building configuration.

Dependent on the overall dimensions and configuration of the buildingunit configuration the location and relative dimensions of the “longsidewalls” and front and rear “end walls” may vary.

From the building unit configuration, the modular assembly can beconverted back into the shipping container configuration by asubstantially reverse automated process to that of converting themodular assembly form the shipping container configuration to thebuilding unit configuration.

In order to facilitate the disposition of the modular assembly intoeither the building unit configuration or the shipping containerconfiguration, the automated erection system is provided. The automatederection system performs an automatic, pre-programmed sequence, by wayof electric motors, gears, pulleys, cables, automated mechanical armsand/or electronic controls to convert the modular assembly between thetwo configurations. The pre-programmed sequence may be stored in acomputer-readable medium and operated by a control processing unit.Examples of computer-readable media include magnetic media such as harddisks, floppy disks, and magnetic tape; optical media such as CD ROMdisks and DVD; magneto-optical media such as optical disks; and hardwaredevices that are specially configured to store and perform programinstructions, such as read-only memory (ROM), random access memory(RAM), flash memory, and the like.

The automated erection system comprises at least three subsystems whichare all located within the container structure above what wouldconstitute the ceiling of the building assembly. The three subsystemsare conceptually identical mechanisms that may vary on the power of theelectrical motors that drive them.

For example, the first mechanism operates a first plurality of cablesthat are released or retrieved by means of a combination of pulleys thatare attached to a pulley carriage that is displaced along a pair orrails by means of a linkage to a threaded bar. The threaded bar isrotated by a combination of gears and a direct current 12 volt electricmotor that can rotate bi-directionally. Depending on the operation, themotor will rotate clockwise or counterclockwise. As the motor rotates,the motor turns the threaded bar and the pulley carriage, which movesalong the threads of the threaded bar, moves as the threaded bar turns.As the pulley carriage moves up or down the threaded bar, the cablesattached thereto are released or retrieved accordingly.

Similarly, the second mechanism having a similar mechanism as the firstmechanism having another combination of pulleys that are attached toanother pulley carriage that is displaced along another pair or rails bymeans of a linkage to another threaded bar operates a second pluralityof cables which in turn operate a plurality of automated mechanicalarms, respectively. In particular, the cables are attached to automatedmechanical arms to lift the arms up and down as will be described later.This mechanism is also bi-directional.

The third mechanism operates a third plurality of cables in a similarmanner, having another combination of pulleys that are attached toanother pulley carriage that is displaced along another pair or rails bymeans of a linkage to another threaded bar to operate a third pluralityof cables. This mechanism is also bi-directional.

The automated erection system may include a processor which processesthe pre-programmed sequence and controls the three subsystems accordingthereto.

In addition, on a “front short end” of the container configuration twoentry panels are respectively hinged to the body of the container. Inparticular, a lower most longitudinal end of a first entry panel ispivotally or hingedly attached to the frame and is selectivelypositioned or pivoted outwardly therefrom in a downward direction torest in a substantially horizontal position to constitutes an entryporch. Also, an upper most longitudinal end of a second entry panel ispivotally or hingedly attached to the frame and is selectivelypositioned or pivoted outwardly therefrom in an upward direction to restin a substantially horizontal position which overlies the entry porchdefined by the first entry panel. Thus, when deployed, the second entrypanel constitutes a canopy for the entry. The two entry panels can be“manually” deployed with the assistance of pneumatic pistons. Accordingto one exemplarily embodiment, access is gained to the control panelfrom where the automated sequence is initiated once the two entry panelsare deployed. When the two entry panels are deployed, an entrancedisposed in the “front short end” is exposed.

The modular assembly may further comprise at least one interiorpartition that is preferably in a fixed position within the frame whenthe unit arrives on site in its shipping container configuration. Anadditional partition can be added, by way of example only, by installingan included partition panel assembly in order to define the interior“rooms” or space within the building unit configuration. The partitionpanel system can be unfolded and secured to the floor, to the interiorof the building unit side wall, and to the at least one fixed partition,as set forth above.

In addition, cabinets can be positioned in a kitchen area using tracksinstalled on the kitchen walls. A water heater can be installed usingpre-existing utility pipes in the modular assembly. Kitchen appliancesand restroom fixtures such as sinks, toilets, oven and stove units, andrefrigerators can be installed into the building unit during assembly.The building unit arrives on site equipped with both interior andexterior connections for water, sewer, and electrical utilities.Furthermore, doors and windows can be installed into the frame and oneor more of the frame or unit panels. Also, one or more doors may bepre-installed into the front or other portions of the modular assemblyand windows may also be installed in appropriate locations.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects of the present invention will become moreapparent from the following description of exemplary embodiments, takenin conjunction with the accompanying drawings of which:

FIG. 1 is a perspective view of an exemplary embodiment of the modularassembly in a shipping container configuration;

FIG. 2 is a perspective view of the exemplary embodiment of FIG. 1 in asuccessive step of assembly from the shipping container configuration toa building unit configuration;

FIG. 3 is a perspective view of the exemplary embodiment of FIGS. 1 and2 in yet another successive step of assembly from the shipping containerconfiguration to a building unit configuration;

FIG. 4 is a perspective view of the exemplary embodiment of FIGS. 1through 3 in yet another successive phase of assembly into the buildingunit configuration;

FIG. 5 is a perspective view of the exemplary embodiment of FIGS. 1through 4 in yet another successive phase of assembly into the buildingunit configuration;

FIG. 6 is a perspective view of the exemplary embodiment of FIGS. 1through 5 in yet another successive phase of assembly into the buildingunit configuration;

FIG. 7 is a perspective view of the exemplary embodiment of FIGS. 1through 6 in yet another successive phase of assembly into the buildingunit configuration;

FIG. 8 is a perspective view of the exemplary embodiment of FIGS. 1through 7 in yet another successive phase of assembly into the buildingunit configuration;

FIG. 9 is a perspective view of the exemplary embodiment of FIGS. 1through 8 in yet another successive phase of assembly into the buildingunit configuration;

FIG. 10 is a perspective view of the exemplary embodiment of FIGS. 1through 9 in yet another successive phase of assembly into the buildingunit configuration;

FIG. 11 is a perspective view of the exemplary embodiment of FIGS. 1through 10 in yet another successive phase of assembly into the buildingunit configuration;

FIG. 12 is a perspective view of the exemplary embodiment of FIGS. 1through 11 in yet another successive phase of assembly into the buildingunit configuration;

FIG. 13 is a perspective view of the exemplary embodiment of FIGS. 1through 12 in yet another successive phase of assembly into the buildingunit configuration;

FIG. 14 is a perspective view of an exemplary embodiment of the modularassembly in a building unit configuration;

FIG. 15 is another perspective view of the exemplary embodiment of themodular assembly in a building unit configuration;

FIG. 16 is a perspective view of an exemplary embodiment of an erectionsystem having three subsystems;

FIG. 17 is another perspective view of the exemplary embodiment of theerection system having three subsystems;

FIG. 18 is another a perspective view of the exemplary embodiment of theerection system, showing only two of the three subsystems;

FIG. 19 is a close-up perspective view of the exemplary embodiment ofthe erection system;

FIG. 20 is a perspective overhead view of the interior of the modularassembly when in the building unit configuration;

FIG. 21 is a perspective overhead view of an exemplary embodiment of theinterior of the modular assembly in building unit configuration withappliances, shelves, cabinets, closets, furnishings and partitions inplace;

FIGS. 22A to 22D are views showing the mechanisms for moving a secondset of panels;

FIG. 23 is a perspective view of a foundation slab used for supportingmodular assemblies according to an exemplary embodiment;

FIG. 24 is a perspective view of an exemplary embodiment of the modularassembly connected to the foundation slab shown in FIG. 23;

FIG. 25 is a perspective view of an exemplary embodiment of the modularassembly connected to the foundation slab shown in FIG. 24;

FIG. 26 is a perspective view of an exemplary embodiment of the modularassembly having connectors configured to receive a second modularassembly stacked on the modular assembly;

FIG. 27 is a perspective view of an exemplary embodiment of a secondmodular assembly stacked on top of a first modular assembly;

FIG. 28 is a perspective view of an exemplary embodiment of connectingsecond modular assembly to the first modular assembly shown in FIG. 27;

FIG. 29 is a perspective view of an exemplary embodiment of a thirdmodular assembly stacked on top of first and second modular assemblies;

FIG. 30 is a perspective view of an exemplary embodiment of a fourthmodular assembly stacked on top of first, second and third modularassemblies;

FIG. 31 is a perspective view of the exemplary embodiment of FIG. 30 ina successive step of assembly from the shipping container configurationto the building unit configuration;

FIG. 32 is a perspective view of the exemplary embodiment of FIGS. 30and 31 in yet another successive step of assembly from the shippingcontainer configuration to a building unit configuration;

FIG. 33 is a perspective view of the exemplary embodiment of FIGS. 30through 32 in yet another successive phase of assembly into the buildingunit configuration;

FIG. 34 is a perspective view of the exemplary embodiment of FIGS. 30through 33 in yet another successive phase of assembly into the buildingunit configuration;

FIG. 35 is a perspective view of the exemplary embodiment of FIGS. 30through 34 in yet another successive phase of assembly into the buildingunit configuration;

FIG. 36 is a perspective view of the exemplary embodiment of FIGS. 30through 35 in yet another successive phase of assembly into the buildingunit configuration; and

FIG. 37 is a perspective view of the exemplary embodiment of FIGS. 30through 36 in yet another successive phase of assembly into the buildingunit configuration.

Throughout the drawings, the same drawing reference numerals will beunderstood to refer to the same elements, features, and structures.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The matters defined in the description such as a detailed constructionand elements are provided to assist in a comprehensive understanding ofthe embodiment of the invention and are merely exemplary. Accordingly,those of ordinary skill in the art will recognize that various changesand modifications of the embodiments described herein can be madewithout departing from the scope and spirit of the invention. Also,descriptions of well-known functions and constructions are omitted forclarity and conciseness.

As shown in the accompanying FIGS. 1 through 15, the modular assembly ofthe present invention is generally indicated as 100 and is structured toassume either a shipping container configuration as represented in FIG.1 or an assembled building unit configuration as represented in FIGS. 14and 15. When in the building unit configuration, the modular assembly100 can be used either as a living unit, commercial unit, or otherfacilities, wherein one or more individuals can occupy the modularassembly 100 and perform any of a variety of different functions.

Accordingly, the modular assembly 100 includes a frame generallyindicated as 12 including a plurality of at least four support members14 interconnected by cross braces or like additional support structures15. The support members 14 as well as the cross braces 15 may be made ofa high strength material such as, but not limited to, tubular steel orother appropriate materials welded or otherwise interconnected to oneanother to form a box-like configuration as represented throughout thevarious Figures.

As will be explained in greater detail hereinafter, the modular assemblyincludes a plurality of frame panels and a plurality of unit panelsmovably connected to the frame 12 and/or to one another and selectivelypositionable into a closed position, as represented in FIGS. 1 and 2, oran opened position as represented in FIGS. 3 through 15. The structuraland operative details of both the frame panels and the unit panels willbe more fully described. However, in order to properly position at leastthe frame panels, and possibly at least some of the plurality of unitpanels, the modular assembly of the present invention also includes anautomated erection system, as shown in FIG. 16.

The automated erection system performs an automatic, pre-programmedsequence by way of electric motors, gears, pulleys, cables, automatedmechanical arms and electronic controls to convert the modular assemblybetween the two configurations.

The automated erection system comprises at least three subsystems (to bedescribed later) which are all located within the container structureabove what would constitute the ceiling of the building assembly. Asshown in FIGS. 16 and 17, the three subsystems are stacked on top of oneanother. The three subsystems are conceptually identical mechanisms thatmay vary on the power of the electrical motors that drive them.

According to FIG. 1, the modular assembly includes on the “front shortend” of the shipping container configuration two entry panels identifiedas 1 and 2, and includes on the “long side” of the shipping containerconfiguration a frame panel 3. The entry panels 1 and 2 are respectivelyhinged to the cross braces 15 of the body of the frame 12. Inparticular, as shown in FIGS. 1-4, a lower most longitudinal end 2 a ofentry panel 2 is pivotally or hingedly attached to the frame and isselectively positioned or pivoted outwardly therefrom in a downwarddirection to rest in a substantially horizontal position to constitutesan entry porch. Also, an upper most longitudinal end 1 a of entry panel1 is pivotally or hingedly attached to the frame and is selectivelypositioned or pivoted outwardly therefrom in an upward direction to restin a substantially horizontal position which overlies the entry porchdefined by the entry panel 2. Thus, when deployed, the entry panel 1constitutes a canopy for the entry. The two entry panels can be“manually” deployed in a controlled rate with the assistance ofpneumatic pistons, spring loaded jack springs, or the like. According toone exemplarily embodiment, access is gained to the control panel fromwhere the automated sequence is initiated once the two entry panels aredeployed. When the two entry panels are deployed, an entrance disposedin the “front short end” is exposed.

As shown in FIG. 2, within the support members 14 located on each cornerof the frame 12 of the modular assembly 100 are extensible columns 16operated by automated electromechanical actuators which lift and levelthe modular assembly 100, raising it, preferably, at least eighteeninches off the ground and adapting it to a variable topography site suchthat the bottom panel (i.e., the floor of the building unit) is level.Thus, the height of each extensible column 16 is adjusted independentlysuch that the structure can be leveled by way of the columns 16 insteadof leveling the terrain itself. A plurality of pressure pads 17 arelocated underneath the support members 15, connected to the ends of theextensible columns 16, to distribute the weight of the modular assembly100 and prevent the extensible columns 16 from sinking into the soil.Not only do the pressure pads 17 help to keep the modular assemblylevel, but also reduces any damage incurred to the land. It ispreferable that only four extensible columns with pressure pads are usedsuch that the impact on the land is reduced further. Motors 41(d),41(e), 41(f) and 41(g), which are coupled to electromechanical columnextension actuators 42 (shown in FIGS. 16 and 17) provide heightadjustment of the extensible columns 16.

As shown in FIGS. 4-6, once the container is raised and leveled by theextensible columns 16, frame panels 3 and 4, which define the outer“long sides” of the frame when the modular assembly 100 is in theshipping container configuration, are released from their uprightposition and are lowered by means of cables 21, 22, 23 and 24 (cable 24not shown in FIGS. 4-6) by the automated erection system. When fullydeployed, the frame panels 3 and 4 make up two floor portions of thebuilding unit configuration, as shown in FIG. 6.

In particular, frame panels 3 and 4 are pivotally or hingedly attachedalong their lower most longitudinal (i.e., horizontal) end 3 a and 4 a(4 a not shown) respectively, to the frame 12 and are selectivelypositioned or pivoted outwardly from their upright position in adownward direction to rest in a substantially horizontal position. Theseframe panels 3 and 4 are lowered (or raised) by a plurality of cables21, 22, 23, 24 attached at one end to upper most longitudinal end 3 band 4 b of the frame panels 3 and 4. Cables 21, 22, 23 and 24 are fedthrough a hole in a corresponding support member 14 and are coupled to apulley carriage 37 a (see FIG. 17 where 37 a(1) shows the pulleycarriage 37 a in a retracted position and 37 a(2) shows the pulleycarriage 37 a in a released position) of the automated erection systemdisposed within the container structure above what would constitute theceiling of the building assembly (see also FIG. 16).

A first mechanism of the automated erection system operates cables 21,22, 23 and 24. As shown in FIGS. 16-18, cables 21, 22, 23 and 24 arereleased or retrieved by means of a combination of pulleys that areattached to the pulley carriage 37 a that is displaced along a pair orrails 38 and 39 by means of a linkage to a threaded bar 40 (see FIG.17). In particular, the release and retrieval of cables 21 and 24 arecontrolled by one pulley carriage 37 a and cables 22 and 23 arecontrolled by another pulley carriage 37 a. The threaded bar 40 isrotated by a combination of gears and a direct current 12-volt electricmotor 41(a) that can rotate bi-directionally for releasing andretrieving the cables 21, 22, 23 and 24. Depending on the operation, themotor 41(a) will rotate clockwise or counterclockwise. As the motor41(a) rotates, the motor 41(a) turns the threaded bar 40 and the pulleycarriages 37(a), which move along the threads of the threaded bar, moveas the threaded bar 40 turns. That is, depending on the operation, themotor 41(a) will rotate clockwise or counterclockwise. As the pulleycarriages 37(a) move up or down the threaded bar 40, the cables 21, 22,23 and 24 attached thereto are released or retrieved accordingly. Inparticular, when the pulley carriages 37(a) are in near the center ofthe rail system at position 37 a(1), the cables 21-24 are in a“retrieved” position. Alternatively, when the pulley carriages 37(a) arein near the ends of the rail system at position 37 a(2), the cables21-24 are in a “released” position. In order to lower the frame panels 3and 4, the cables 21-24 are controllably released from the “retrieved”position into the “released” position.

FIG. 19 shows one exemplary embodiment of the motor 41(a) coupled to thethreaded bar 40 by a gear 43 and chain 44 used for turning the threadedbar 40.

In addition to the above, the modular assembly further comprises aplurality of unit panels at least some of which are movably connected tothe frame 12 and initially disposed on the interior thereof when themodular assembly 100 is in the shipping container configuration.

FIGS. 6-8 show a first set of the plurality of unit panels 7 and 8 whichare exposed after the frame panels 3 and 4 are deployed from theirshipping container configuration. The first set of the plurality of unitpanels 7 and 8 are pivotally or hingedly attached along their upper mostlongitudinal (i.e., horizontal) end 7 a and 8 a (8 a not shown) to theframe 12 and are selectively positioned or pivoted outwardly therefromin an upward direction to rest in a substantially horizontal position,into a position which overlies the floor portion defined by theaforementioned frame panels 3 and 4. Thus, when deployed, the first setof the plurality of unit panels 7 and 8 form a ceiling portion of thebuilding unit configuration. The first plurality of unit panels 7 and 8are raised (or lowered) by a plurality of automated mechanical arms 33,34, 35 and 36 (mechanical arms 33 and 36 not shown) which are controlledby a plurality of cables of the automated erection system.

In particular, a second mechanism shown in FIGS. 16 and 17 of theautomated erection system operates cables 25, 26, 27 and 28 which inturn operate mechanical arms 33, 34, 35 and 36, respectively.

The second mechanism has a similar mechanism as the first mechanismhaving another combination of pulleys that are attached to another setof pulley carriages 37(b) (not shown) that are displaced along anotherpair or rails 38 and 39 by means of a linkage to another threaded bar 40to operate a second plurality of cables 25-28 which in turn operate aplurality of automated mechanical arms 33-36, respectively. Inparticular, as the motor 41(b) turns the threaded bar 40, the cables25-28 are retrieved or released in a similar manner as described abovein conjunction with the first mechanism. The cables 25-28 are attachedto the automated mechanical arms 33-36 to lift the arms up and down (seeFIG. 16). In particular, as shown in FIGS. 7, 8 11 and 16, when thepulley carriages 37(b) are moved from a “released” position 37 b(2) to a“retrieved” position 37 b(1), the mechanical arms 33-36 are pulledupward and are deployed, lifting the unit panels 7 and 8. The mechanicalarms 33-36 can be lowered again by moving the pulley carriages 37(b)from the “retrieved” position 37 b(1) to the “released” position 37b(2).

Further, each of the side panels of the plurality of frame panels 3 and4 include panel segments 5 and 6 initially disposed in overlyingconfronting relation to respective ones of the frame panels 3 and 4. Thepanel segments 5 and 6, shown in FIGS. 5, 6 and 9-12, of a correspondingone of the frame panels 3 and 4 or side panels are hingedly or pivotallyattached at the upper most longitudinal end 3 b and 4 b of the framepanels 3 and 4 (i.e., at the upper most longitudinal end of a framepanel when positioned in the shipping container configuration) so as toextend outwardly in an upward direction from the corresponding framepanel 3 and 4 into a substantially upright (i.e., vertical) position.The panel segments 5 and 6 are raised (or lowered) by a plurality ofcables 29, 30, 31 and 32 of the automated erection system. These cables29, 30, 31 and 32 are threaded through the panel structure of panels 5,6, 7 and 8; they are anchored on the corners of frame panels 3 and 4 andpulled by the mechanisms located within the container structure (i.e.,by the automated erection system), as shown in FIG. 9.

In particular, a third mechanism of the automated erection systemoperates cables 29, 30, 31 and 32 (see FIGS. 16-18). The third mechanismis also bi-directional such that the plurality of cables 29, 30, 31 and32 can be retrieved (to pull the panel segments 5 and 6 to the uprightposition) and released (to lower the panel segments 5 and 6).

The third mechanism has a similar mechanism as the first and secondmechanisms having another combination of pulleys that are attached toanother set of pulley carriages 37(c) (not shown) that are displacedalong another pair or rails 38 and 39 by means of a linkage to anotherthreaded bar 40 to operate a third plurality of cables 29-32. As motor41(c) turns the threaded bar 40, the cables 29-32 are retrieved orreleased in a similar manner as described above in conjunction with thefirst and second mechanisms. In particular, the panel segments 5 and 6are moved to their upright position when the pulley carriages 37(c) aremoved from a “released” position 37 c(2) to a “retrieved” position 37c(1), and the panel segments 5 and 6 are lowered when the pulleycarriages 37(c) are moved from the “retrieved” position 37 c(1) to the“released” position 37 c(2).

Further, when erected to the substantially upright position, FIGS. 9 and10 show that a longitudinal edge or portion 5 a and 6 a of the nowupright panel segments 5 and 6 are connected to and support acorresponding outer longitudinal edge 7 b and 8 b of the first set ofthe plurality of unit panels 7 and 8. With panel segments 5 and 6 inposition, unit panels 7 and 8 rest on panel segments 5 and 6 and on thehinges that attach the unit panels 7 and 8 to the frame 12 of thecontainer structure. At this point, since unit panels 7 and 8 areproperly supported, the mechanical arms 33, 34, 35 and 36 are loweredand stowed in a second set of the plurality of unit panels 9, 10, 11 and12, respectively, as shown in FIGS. 11 and 12 (unit panels 11 and 12 notshown).

As such each of the combined or directly associated frame panels 3 and 4and panel segments 5 and 6 collectively define a corresponding floorportion and long sidewall portion of the building unit configuration.Furthermore, the first set of the plurality of unit panels 7 and 8define a corresponding ceiling portion supported by the long sidewallportion of the building unit configuration (i.e., by the uprighted panelsegments 5 and 6).

Additionally, a second set of the plurality of unit panels 9, 10, 11 and12 shown in FIGS. 12-14 (unit panels 11 and 12 not shown) may also bemovably connected to the frame 12 and are at least initially disposed onthe interior thereof when the modular assembly 100 is in the shippingcontainer configuration. In particular, the second set of the pluralityof unit panels 9, 10, 11 and 12 are exposed after the first set of theplurality of unit panels 7 and 8 are deployed from their shippingcontainer configuration. In at least one exemplary embodiment, thesecond set of the plurality of unit panels 9, 10, 11 and 12 may bepivotally or hingedly connected along a latitudinal (i.e., vertical)edge 9 a, 10 a, 11 a and 12 a or side thereof to the frame structure 12(e.g., to a support member 14 of the frame structure 12) and may extendoutwardly so as to respectively define front wall portions and rear wallportions of the building unit configuration. The second set of theplurality of unit panels 9, 10, 11 and 12 are simultaneously rotatedoutward, to assume their positions as front wall and rear wall portionsof the building configuration, as shown in FIG. 14. The unit panels 9,10, 11, 12 are rotated by means of a mechanism that includes a motor(not shown), a threaded bar (not shown) rotated by the motor, andscissor jacks 101. The motor and threaded bar are similar to the variousmotor/bar configurations discussed above. As shown in FIGS. 22A-22D, thescissor jacks 101, which are located on the ends of the container,either push or pull the levers 102, which respectively rotate the unitpanels 9, 10, 11, 12. The levers 102 also pull along a segment 103 ofthe ceiling that covers the void left by the unit panels once they aredeployed. Similarly, the ceiling segments 103 are returned to theirinitial position when the panels 9, 10, 11, 12 are “folded” back intothe container configuration.

All motors, including motors 41(a)-41(g) are electrically coupled to acontrol processing unit, which controls the operation thereof accordingto the pre-programmed sequence stored therein. The pre-programmedsequence may be initiated by a user through an input device, and eachmotor can operate independently from the others.

When all the panels have been deployed to the building configuration,cables 29, 30, 31 and 32, which are threaded through the panel structureof panels 5, 6, 7 and 8, are tensioned to lock all the panels intoposition and create a post-tensioned structure. Once the post tensioninghas been completed, cables 21, 22, 23 and 24 are released from panels 3and 4 and retracted into the container structure, as shown in FIG. 15.

Dependent on the overall dimensions and configuration of the buildingunit configuration the location and relative dimensions of the “longsidewalls” and front and rear “end walls” may vary.

From the building unit configuration, the modular assembly can beconverted back into the shipping container configuration by asubstantially reverse automated process to that of converting themodular assembly form the shipping container configuration to thebuilding unit configuration.

As set forth above, in order to facilitate the disposition of themodular assembly 100 into either the building unit configuration or theshipping container configuration the automated erection system isprovided. The automated erection system performs an automatic,pre-programmed sequence by way of electric motors, gears, pulleys,cables, automated mechanical arms and electronic controls, and the liketo convert the modular assembly between the two configurations. Thepre-programmed sequence may be stored in a computer-readable medium.Examples of computer-readable media include magnetic media such as harddisks, floppy disks, and magnetic tape; optical media such as CD ROMdisks and DVD; magneto-optical media such as optical disks; and hardwaredevices that are specially configured to store and perform programinstructions, such as read-only memory (ROM), random access memory(RAM), flash memory, and the like. Thus, the modular assembly 100 can beconverted between the two configurations quickly and easily withoutspecial equipment.

When fully assembled into the building unit configuration of FIG. 15,the interior thereof is represented, for example, in FIGS. 20 and 21.The interior of the building unit configuration is preferably, but notexclusively, formed into a plurality of sections 40, 42 and 44 at leastpartially separated from one another. However, the sections 40, 42 and44 are disposed in communicating, accessible relation with one anotherin order to allow occupants to pass easily between the various sections40, 42 and 44. At least partially segregating the sections 40, 42 and 44is a partition assembly 46 and 48, which effectively defines interiorwall portions of the building unit configuration. The partitions orinterior wall units 46 and 48 separate what may be referred to as aprimary or main room 50 and kitchen or utility area 52 from separate, atleast partially segregated bedrooms or other room areas 54 and 56. Also,a bathroom area generally indicated as 60 may also be defined by theinterior walls or partitions 46 and 48.

In addition to the above various appliances or utilities may be includedin appropriate portions of the interior of the building unitconfiguration. Such additional appliances or facilities may includekitchen cabinets which can be affixed to the kitchen or other utilityarea 52 by means of tracks or like coupling or installation structures.In addition, water, sewer and electric utility connections as well asappropriate sinks, bathing facilities, stove or ranges, refrigerators,air conditioners, etc. may also be appropriately positioned on theinterior of the building unit construction as generally represented inFIG. 15.

In addition appropriate windows 70, door(s) 72, doorways, halls orpassageways (see FIGS. 20 and 21) are pre-structured and appropriatelydisposed in the various portions of the frame 12, partitions 46 and 48,panel segments 5 and 6 or unit panels defining the end walls as 9, 10,11 and 12.

The mechanisms that transform the modular assembly from a shippingcontainer configuration to a building unit configuration have beendesigned so that there are no elements that project beyond the planesthat define the building unit configuration. This allows thetransformation of the modular assemblies between the two configurationseven when they are stacked vertically, the modular assemblies can bestacked and grouped together to from multi-story buildings quickly andefficiently.

The ability to stack and interconnect the modular assemblies while inthe shipping container configuration simplifies the construction processand greatly reduces the risks by not having to stack the units whilefully deployed. Even the utilities can be connected while the units arestacked in the shipping container configuration since the modularassemblies have factory installed piping and wiring with connectionpoints readily accessible at the rear of the assembly, making it verysimple to connect to the risers installed on site.

A foundation for these buildings is a prefabricated reinforced concreteslab designed to comply with local building codes, soil conditions andstructural considerations, anchoring of the modular unit to thefoundation slab can be achieved in many ways. One exemplary way isdescribed later. However, the anchoring system should be designed tocomply with the structural requirements of the erection site andadditional structural reinforcements will be specified for sites wheredynamic loads must be taken into consideration (e.g., wind andearthquakes), the addition of these elements does not alter the basicerection procedure.

The vertical and horizontal circulation modules for the building unitconfiguration are not shown at this point since they vary according tothe layout of the stacked unit modules. They are, however, also modularand are deployed and connected to the unit modules with the same ease asthe stacking of the modular assemblies.

Another feature of this stackable configuration is that it is just aseasily disassembled, and can be relocated using the same components,including the foundation slab, for emergency situations in high densityurban areas. These multi-story building assemblies can be erected onborrowed or leased pieces of land and removed when the emergencysituation has been resolved.

FIG. 23 shows a prefabricated foundation slab 200 used for supportingmodular assemblies. In particular, the foundation slab is useful ininstances when stacking two or more modular assemblies on top of eachother to form multi-story buildings because the foundation slab providesan added foundation for supporting the weight of the multi-storystructure. In the case of a multi-story building, a base surface of acentral frame of the lower most modular assembly is disposed on thefoundation slab. The size and reinforcement of the foundation slab maydepend on the quality of the soil and local construction codes.

The foundation slab may include a plurality of connectors 201 integratedtherein and which connect to the central frame of the modular assembly.The central frame, for example, may have openings for receiving theconnectors.

FIG. 24 shows a first modular assembly 100 a similar to that shown inFIGS. 1-15 connected to the foundation slab 200 shown in FIG. 23. Inparticular, a base surface and an upper surface of the central frame ofthe modular assembly include a plurality of openings 202 which areconfigured to receive connectors, including connectors 201. The openingsdisposed on the upper surface of the central frame are configured to beconnected to the openings disposed on the base surface of anothermodular assembly stacked thereon via connectors.

FIG. 25 shows additional connectors 203 fixed to the modular assembly100 a and the foundation slab 200.

FIG. 26 shows connectors 207 which are inserted between a two modularassemblies. In particular, connectors 207 are inserted in the openings202 of the two modular assemblies in order to link the two modularassemblies together and to stabilize the upper modular assembly on thelower modular assembly.

FIGS. 27 shows a second modular assembly 100 b stacked on top of thefirst modular assembly 100 a, both in the shipping containerconfiguration. Each modular assembly may have additional side openings208 for receiving side connectors 209 shown in FIG. 28 for coupling thefirst modular assembly 100 a and the second modular assembly 100 btogether.

FIGS. 29 shows a third modular assembly 100 c stacked on top of thefirst modular assembly 100 a and the second modular assembly 100 b, eachin the shipping container configuration.

FIGS. 30 shows a fourth modular assembly 100 d stacked on top of thefirst, second and third modular assemblies 100 a, 100 b and 100 c, eachin the shipping container configuration. Additional modular assembliesmay be added in a similar manner.

Each modular assembly 100 a, 100 b, 100 c and 100 d can be transformedbetween the shipping container configuration and building unitconfiguration after stacking and securing the modular assemblies. Eachmodular assembly can be operated, and thus transformed, independently ofthe other modular assemblies.

FIG. 31 shows a successive step of assembly from the shipping containerconfiguration to the building unit configuration, wherein each modularassembly 100 a, 100 b, 100 c and 100 d has a configuration similar tothat shown in FIG. 4 where a front porch and roof are deployed.

FIG. 32 shows another successive step of assembly from the shippingcontainer configuration to the building unit configuration, wherein eachmodular assembly 100 a, 100 b, 100 c and 100 d has a configurationsimilar to that shown in FIG. 6 where floor panels are deployed.

FIG. 33 shows another successive step of assembly from the shippingcontainer configuration to the building unit configuration, wherein eachmodular assembly 100 a, 100 b, 100 c and 100 d has a configurationsimilar to that shown in FIG. 8 where roof panels are deployed.

FIG. 34 shows another successive step of assembly from the shippingcontainer configuration to the building unit configuration, wherein eachmodular assembly 100 a, 100 b, 100 c and 100 d has a configurationsimilar to that shown in FIG. 10 where side walls are deployed.

FIG. 35 shows another successive step of assembly from the shippingcontainer configuration to the building unit configuration, wherein eachmodular assembly 100 a, 100 b, 100 c and 100 d has a configurationsimilar to that shown in FIG. 14 where front and back panels aredeployed.

FIG. 36 shows another successive step of assembly from the shippingcontainer configuration to the building unit configuration, wherein eachmodular assembly 100 a, 100 b, 100 c and 100 d has a configurationsimilar to that shown in FIG. 15 where cables are retracted.

FIG. 37 shows another successive step of assembly from the shippingcontainer configuration to the building unit configuration, wherein eachmodular assembly 100 a, 100 b, 100 c and 100 d has a configurationsimilar to that shown in FIG. 36, except reinforcement rails 220 areadded vertically at each corner of the multi-story structure to addadditional support to the structure. For example, the reinforcementrails may be installed in accordance with local construction codes, andto resist dynamic forces such as wind (e.g., hurricanes) and soilmovements (e.g., earthquakes). In FIG. 37, an angled rail is used in thefour corners of the cantilevered sides to tie together the units, thuscreating a more rigid structure.

Because many modifications, variations and changes in detail can be madeto the described preferred embodiment of the invention, it is intendedthat all matters in the foregoing description and shown in theaccompanying drawings be interpreted as illustrative and not in alimiting sense. Thus, the scope of the invention should be determined bythe appended claims and their legal equivalents.

1-31. (canceled)
 32. A building assembly comprising: a plurality ofmodular assemblies stacked on top of each other in the shippingcontainer configuration, each modular assembly structured to assumeeither a shipping container configuration or a building unitconfiguration and including a central frame which defines a box-shapedshipping container; a plurality of frame panels disposable in asubstantially closed, interconnected position to at least partiallydefine the shipping container; the plurality of frame panels moveablydisposed outwardly from the frame into an opened position to at leastpartially define the building unit configuration; a plurality of unitpanels movably connected to and disposable on the frame in a closedposition aligned with the frame panels being in the closed position; andthe plurality of unit panels movably disposable outwardly from the frameinto fan opened position to further at least partially define thebuilding unit configuration, wherein the central frame comprises aplurality of fixed interconnected columns which form an exterior frameof the modular assembly when the modular assembly is in the shippingcontainer configuration, the plurality of fixed interconnected columnsof the central frame form a frame of a core structure of the modularassembly when the modular assembly is in the building unitconfiguration, wherein each modular assembly of the plurality of modularassemblies is converted between the shipping container configuration andthe building unit configuration by the automated erection system whiledisposed in a stacked position.
 33. The building assembly according toclaim 32, wherein each modular assembly includes an automated erectionsystem which converts the modular assembly entirely between the shippingcontainer configuration and the building unit configuration, and viceversa, according to an automatic, pre-programmed sequence that isinitiated by a single input, wherein the automated erection system iscoupled to each of the plurality of frame panels and to each of theplurality of unit panels to change the disposition thereof according tothe pre-programmed sequence.
 34. The building assembly according toclaim 33, wherein each of the plurality of frame panels is moveablyconnected along a lower most longitudinal end to the central frame andpositioned to define a floor portion of the building unit configuration,and the automated erection system includes a first plurality of cablesattached at one end to an upper most longitudinal end of individual onesof the plurality of frame panels and attached at another end to a pulleycarriage that is displaced according to the pre-programmed sequence.wherein the each of the plurality of frame panels includes at least onepanel segment movably connected to a corresponding frame panel of theplurality of frame panels and positionable outwardly therefrom tofurther at least partially define a sidewall potion of the building unitconfiguration, the at least one panel segment is moveably connected atan upper most longitudinal end of the corresponding frame panel, and theautomated erection system includes a second plurality of cables whichare threaded through the at least one panel segment and are displacedaccording to the pre-programmed sequence.
 35. The building assemblyaccording to claim 34, wherein the plurality of unit panels includes afirst set of unit panels movably connected along an upper mostlongitudinal end to the central frame and positionable outwardlytherefrom into the opened position to define different ceiling portionsof the building unit configuration, and the automated erection systemincludes a plurality of automated mechanical arms controlled by a thirdplurality of cables and the plurality of automated mechanical arms arecoupled to the first set of unit panels to change the dispositionthereof according to the pre-programmed sequence.
 36. The buildingassembly according to claim 35, wherein the plurality of unit panelsincludes a second set of unit panels movably connected along alatitudinal end to the central frame and positionable outwardlytherefrom into the opened position to collectively define front and rearend wall portions of the building unit configuration, and the automatederection system includes a plurality of electromechanical columnactuators, each of the plurality of electromechanical actuators rotatesone of the second set of unit panels to change the disposition thereofaccording to the pre-programmed sequence.
 37. The building assemblyaccording to claim 32, wherein a lowermost modular assembly is supportedby only four support members which extend from the central frame andelevate the modular assembly from a terrain when the modular assembly isin the building unit configuration.
 38. The building assembly accordingto claim 37, wherein each of the other modular assemblies is supportedby only four support members which extend from the central frame andelevate the modular assembly from another respective modular assembly.